The Official 356Talk Forum

Not for Concourse Engines ,
For Racers, now we are Casting 3D print Carrera 2 liter or 1500/1600 cc Engine Fans
Engineering analysis done at 20,000rpm.Fan blades are 2mm thick and 2 liter fan one Lb. lighter than original manufactured one.
And 1500/1600 cc one very close to original factory weight.
If Interested, Please call or email Bob Garretson.
4 Cam Cooling

Ibrahim Kuzu wrote: ↑Sat Aug 27, 2022 2:33 pm now we are Casting 3D print Carrera 2 liter or 1500/1600 cc Engine Fans

Hi Ibrahim, just interested in the process. Is the fan generated by 3D print used to make sand castings, or what?

Hi Dave,
It is a 3D sand print ,than material Poured in ...One pattern one part ..If you do bad pouring (material temperature, Weather temperature, how fast you are going etc) all have effect on the end result...Our yield is around 4/1 meaning 4 good pour one bad one goes back to fire...
Due to very critical special part. ( Casting 2mm fan blades not every ones cake to eat....) .Than We machine the needed surfaces to the factory specs.

Very cool Ibrahim, thanks for sharing!

Thank you Joris,
Happy to be in the crowd of the special guys like, Mike Smith,Bob Garretson,Jacques Lefriant and others taking their time to make these non-existing Carrera parts
to keep the 356 Carrera faith going .

It’s lost wax casting? Your rejection rate sounds good to me.

Hi Martin ,
Not wax casting.3D sand print Core Pattern .Wax casting also can be used in the choice ..But ours is Sand Print cores .

There is a 3D print material that is a plastic, but behaves like wax when hot metal is poured into the mold. Is that what you are using Ibrahim?

Hi Jim,
We are not using Plastic.
It is Sand Core.
Please call me if you need more details.
IK

Ibrahim

Maybe I wasn't clear. There is a material that you 3D print that is plastic. It is then placed in a sand cast mold, the metal is poured into the mold and the 3D printed plastic part melts just like wax would.

That is essentially a lost wax method, but this is quite different. Apparently the sand is printed into a mold shape leaving a very accurate cavity to pour the aluminum into. It’s one of those modern technologies that sounds nearly impossible but it works and is used commercially.

Hi Jim,
Just like Martin explained.
Thanks Martin...
IK

I’m an expert now after reading various things from Google.

Ibrahim, one point of clarification: does the 3d printing produce the pattern, which then is used to make the mold, and removed? Or does the 3d printing generate the mold directly? If the latter, then I think that implies the 3d printer is generating each grain of sand and it is also generating the binder to hold the grains together... Is the sand traditional silica sand or something else? Any way you look at it its pretty remarkable.

I found this, which might help explain the process: https://www.humtown.com/3d-printed-sand-cores-molds